Low-volume production

For industries like aerospace and defense, where highly complex parts are produced in low volumes, 3D printing is ideal. Using the technology, complex geometries can be created without having to invest in expensive tooling equipment. This offers aerospace OEMs and suppliers a cost-effective way to produce small batches of parts cost-effectively.

Weight reduction

Alongside aerodynamics and engine performance, weight is one of the most important factors to consider when it comes to aircraft design. Reducing the weight of an aircraft can significantly reduce its carbon dioxide emissions, fuel consumption and payload.

This is where 3D printing comes in: the technology is an ideal solution for creatinglightweight parts, resulting in considerable fuel savings. When coupled with design optimisation tools likegenerative designsoftware, the potential for increasing the complexity of a part is almost limitless.

Material efficiency

Since the 3D printing process works by producing parts layer by layer, material is, for the most part, used only where needed. As a result, it produces less waste than traditional subtractive methods.

The selection of available 3D printable materials for aerospace and defence applications ranges from engineering-grade thermoplastics (e.g. ULTEM 9085, ULTEM 1010, PAEK, reinforced Nylon) to metal powders (high-performance alloys, titanium, aluminium, stainless steel).

The range of available 3D printable materials is constantly expanding, unlocking advanced aerospace applications.

Part consolidation

One of the key benefits of 3D printing is part consolidation: the ability to integrate multiple parts into a single component. Reducing the number of parts needed can significantly simplify the assembly and maintenance process by reducing the amount of time needed for assembly.

Maintenance & repair

The average lifespan of an aircraft can range between 20 and 30 years, making maintenance, repair and overhaul (MRO) an important function in the industry. Metal 3D printing technologies likeDirect Energy Depositionare commonly used to repair aerospace and military equipment. Turbine blades and other high-end equipment can also be restored and repaired by adding material to worn-out surfaces.